TZ.O.R.C R.O.

PROJECT

DOC. No.: FS-001 Page 1 of 12

Steel Structure
Fabrication Procedure

001 1400/01/21

Rev. DATE PURPOSE OF ISSUE PREPARED CHECKED APPROVED

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TABLE OF CONTENTS

Page
1) SCOPE 4
2) REFERENCES 4
3) UNITS 5
4) SHOP PAINTING 5
5) MATERIALS 6
6) FABRICATION 7

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SCOPE (1
This Specification covers the general requirements for fabrication and inspection of steel
. structures
This specification shall be applied to steel structure work for buildings, pipe racks, shelters ,bridge
and other works related to steel-structure work.Ro project located in Tabriz refinery

REFERENCES (2
In this Specification the following standards and codes have been referred to, and to the extent
.specified, form a part of this Specificatio

ASTM/ASMESection II A ,C , Edition 2019 , latest Add -

. ANSI/AWSD1.1Structural welding cod - steel 2015 -

AWSA5.1 Specification for carbon steel electrodes for shielded metal arc welding -

- AWSA5.18 Specification for carbon steel electrodes for gas metal arc welding

PQR is based on the standard ASME SEC IX

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3) UNITS
This Specification is based on International System of Units (SI), except where otherwise
specified.

4) SHOP PAINTING

General Requirements ( 4.1

Shop painting and surface preparation shall be in accordance with the provisions of the
. "STANDARD SSPC " of the Sweden Institute of Steel Construction, Inc
Unless otherwise specified, only steelwork in contact with concrete need not be painted; all other
steelwork shall be given at least one coat of shop paint.
Any galvanizing or paint, which is damaged by field welding, shall be repaired by touch up
painting.

Inaccessible Surfaces ( 4.2

Except for contact surfaces, surfaces inaccessible after shop assembly shall be cleaned and painted
. prior to assembly, if required by design documents

Contact Surfaces ( 4.3

Paint is permitted unconditionally in bearing -type connections. For slip-critical connections, the
fraying surface requirements shall be in accordance with the RCSC "Specification for Structural
. (Joints Using ASTM 325 or A490 Bolts", Paragraph 3. (b

Finished Surfaces ( 4.4

Machine-finished surfaces shall be protected against corrosion by a rust inhibiting coating that can
be removed prior to erection, or which has characteristics that make removal prior to erection
. unnecessary

Surface next to welds ( 4.5

Prior to painting, weld slag and weld spatter shall be completely removed and the surface shall be
.thoroughly brushed down to ensure complete cleanliness

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5) MATERIALS

Materials of construction shall be per ASME standard

5.1) Steel Type
All material shall conform to the engineering specification "structural Design criteria" All
steel material shall be new and shall be well and cleanly rolled to the dimensions,
section and weights specified.
All structural steel shall be of type ASTM A 36 with a min yield strength of fy=2400 kg/cm2 unless
noted otherwise.

Bolt Type ( 5.2

. Bolts for structural joints shall conform to ASTM A-193 B7 or alternate equivalent

Nut Type ( 5.3

Nuts for normal type and for high strength types shall conform to ASTM A-194 2H or alternate
. equivalent

Washer Type ( 5.4

. Washers-shall conform to ASTM F-436 or alternate equivalent

Storage and Handling ( 5.5

All structural steel shal
l be stored and handl
ed so that members are not subjected to excessive
. stress or damage
. Steel shall be stored in a water tight and dry place until ready for use -
Electrodes
Filler Metal shall be stored ni their original packets or cartons in a dry place adequately protected
. from weather effects
If electrodes become affected by dampness but are not otherwise damaged, they may be used
after being dried Just First time, cut in a manner approved by the electrode Manufacturer.
Electrodes shall be of type E70 XX or equivalent unless otherwise noted and ER 70S-6

Fireproofing ( 5.7
.Fireproofing of structural steel members shall be marked on construction drawings

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6) FABRICATION
6.1) General
All dimensions and lengths of steel members, before commencing fabrication operation
shall be checked and verified.
All material, before and after fabrication shall be straight unless required to be of curvilinear
from, and shall be free from twists.
Sizes of members shall not be substituted without prior approval.
End of beams, channels and other parts abutting against or upon other parts shall be cut to
exact lengths and true and square so as to provide a good bed or joints as the case may be.
Edges of web plates shall be flush with the face of the flange angles, and stiffeners shall fit
closely against the flanges.
Bolt heads and ends of eye rods shall not be welded on butt formed out of the solid metal.
Structures partly or entirely supporting pressure vessels shall be bolted to cleats or
brackets fabricated and assembled by the vessel Manufacturer, except where otherwise specified
on the drawings. Prior approval of site engineer must be obtained for any welding

done to pressure vessels.

For steel structures, which will be exposed to a corrosive environment in service,
surface preparation must be done by blast cleaning. Blast cleaning shall be done in dry
atmosphere after fabrication. Maximum decrease in thickness of so cleaned surface shall not
exceed 0.1 mm. first coat of paint shall be applied before corrosion occurrence

6.2) Preparation of Material

Thermal cutting of structural steel may be by hand or mechanically guided means provided
that the temperature of heated parts of material not exceeds 565c for high strength steel
and 650c for ordinary steels.

6.3) Dimensional Tolerances

For allowable dimensional tolerance as following below table.
Row Profiles Standard
1 U Profiles DIN 1026
2 L Profile DIN 1028
3 IPE Profile DIN 1025
4 Plate DIN 1017

6.4) Cambers
Beams and trusses detailed without specified camber are fabricated so that after erection

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any camber due to rolling or shop fabrication is upward

Cutting ( 6.5
Cutting may be by shearing, cropping, sawing or machine flame cutting. It has a high Gringing
And brush with a flame with a scale of 1.5 millimeters., subject to the approval of site engineer.
Sheared or cropped edges shall, if necessary, be dressed to a neat workmanlike finish and shall be
free from distortion . where parts are to be in metal-to-metal contact

Holing ( 6.6
All holes shall be accurately marked off from template of corresponding plate, and drilled, except
in plates 10 mm thick or under when they may be punched. Holes shall be cleaned from burrs or
. rough edges and countersunk where required

Assembly ( 6.7
The component parts shall be assembled in such a manner that they are neither twisted nor
otherwise damaged, and shall be so prepared that the specified cambers, if any, are provided. All
tubular members shall be sealed so as to prevent the access of moisture to the inside of the
. members

Bolting ( 6.8
Where necessary, washers shall be tapered or otherwise suitably shaped to give the heads and
nuts of bolts a satisfactory bearing. The threaded portion of each bolt shall project through the nut
. at least one thread
A close tolerance or turned bolt shall be of sufficient length to avoid any threaded portion being
within the thickness of the connected parts that is required to develop the bearing load on the bolt,
and shall be provided with a washer or washers, under t he nut, of sufficient thickness to ensure
that at least one full thread (in addition to the thread run -out) remains clear between the nut and
. the unthreaded shank
Where a tubular member is drilled to take bolts or studs, provision shall be made to prevent the
access of moisture to the interior of the tube. For example, a transverse sleeve can be inserted
. where a bolt passes through a tube, or grommets can be used under heads and nuts

Welding ( 6.9
Reasonably smooth and uniform as welded surfaces are acceptable on all welds exposed to view.
Butt and plug welds do not project more than 3 mm above the exposed surface. No finishing or
grinding is required except where clearances or fit of other components may

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. necessitate, or when specially required by the contract documents
The technique of welding, the workmanship, appearance and quality of welds and methods used
in correcting nonconforming work shall be in accordance with section S3 and 4 of the AWS D 1.1
structural welding code – steel". Welding procedure qualifications, when required by the code"
(ASME Sec IX) shall be carried out, using representative samples of materials to be used in the
. work
. Shop paint on surfaces adjacent to welds shall be wire brushed to reduce paint film to a minimum
Welding shall not be undertaken when surfaces to be welded are wet unless the necessary
precautions are taken; welding shall not be carried out when rain or snow is falling. In dusty
conditions, or during period of high wind Welding shall not be carried out on any surface, the
. temperature in the immediate vicinity of which before welding is lower than -18 0c
In above mentioned conditions, the welding process is permitted to be continued, considering
n e c e s s a r y protections of welding area against wind, and rain, etc. a c c o r d i n g t o
. (recommendations of A.R. (Authorized Representative
The welded joint shall be free from defects. Defective portions shall be removed, re -welded and
then re-inspected. Serious undercutti ng shall be made good by the deposition of additional weld
metal. All welding equipment and methods including protection shall be to the satisfaction of the
. A.R

Qualification and testing of welders ( 6.9.1

All welding of structural steel shall be done by qualified welders as per AWS D.1.1 section 4 part
. "C" and approved welding procedure
The welder test shall include specimen weld details representative of the actual construction which
. shall be welded in a manner simulating the condition liable to occur i n the particular fabrication
Reasonably smooth and uniform as welded surfaces are acceptable on all welds exposed to view
Butt and plug welds do not project more than 1.6 mm above the exposed surface. No finishing or
grinding is required except where clearances or fit of other components may necessitate, or when
specially required by the contract documents. Welding shall be according to AISC and AWS
. structural welding codes

Limitation ( 6.9.2
The minimumsize of fillet welds shall be AS per Drawing unless noted otherwise .

Themaximum size of fillet welds that is permitted along the edges of connected parts shall 
: be
, Thethicknessof base metal, for metal less than 6.4 mm thick a)
1.6mm less than the thickness of base metal, for metal 6.4 mm or more in b)

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 thickness, b unless the weld is especially designated on the drawing to be built
out to obtain full-throat thickness.
 Welding shall not be done when:
a) The ambient temperature is lower than 5°C;
b) Surfaces are wet or exposed to rain or snow;
c) High wind occurs or when the welders are exposed to inclement conditions.
 Weld beads would be cleaned by power brushing and chipping between layers and before back
welding double welded joints.
 If the weld length is not shown, full length shall be welded.
 Groove welds shall be subjected to non-destructive testing of radiographic or ultra-sonic types.
 Surfaces and edges to be welded shall be smooth, uniform and free from fines, tears, cracks and
other discontinuities which would adversely affect the quality or strength of the weld.
 Except for the situations mentioned as "special" in the drawings and documents, all surfaces within
a 50 mm distance of welding area, shall be cleaned of harmful materials or materials which
produce hazardous gas during welding.
 In order to prevent stresses and unexpected deformations while welding webs to flanges, welding
shell be applied alternately on both sides of web at a maximum length of 500 mm .
 In cases where more than one pass is required each pass shall be applied alternately as well as
side alternates.
Surfaces to be welded and surfaces adjacent to a weld shall also be free from loose or
thick scale slag, rust, moisture, grease and other foreign materials that would prevent
proper welding.

6.9.3) Acceptance
Acceptance of the weld and material shall be in accordance with relevant standards.

6.9.4) Inspection & Testing

Inspection & testing for fabrication of steel structure are
Welder'sQualificationtest 
WeldingprocedureQualification Test 
Visualinspection 
Dimensionalinspection 
( Non-Destructivetest ( PT, MT,UT 
Paintinginspection - Final inspection - Packing 
inspectio

6.9.5) Inspection and testing status

a) The main Non- destructive testing (NDT) of welds would be penetration & ultrasonic testing

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 (UT&PT).
b) Percentage of test should be increased to 75% to 100% based on decision of inspector if there
is any defect more than specified.

percentage of NDT for butt welds

Part
columns & crane
Test type girders
VT + DT 100%
UT Butt Welds 50%

percentage of NDT for partial penetration & fillet welds

Part
ALL PARTS
Test type
VT + DT 100%
PT or MT 20%

UT: ULTRASONIC TEST

PT: PENETRATION TEST
MT:MAGNETIC PARTICLE TEST
VT: VISUAL TEST
DT: DIMENSIONAL TEST

7) CONTROL OF NON-CONFORMANCES

The vendor has to implement procedures for control and issue of non-conformances to the
Project Quality Plan.
Reporting of non-conformances which are not identified during internal audit, shall be the
responsibility of the relevant Discipline Managers. It shall be the responsibility of the relevant

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Discipline Manager or his representative to institute corrective actions for reported non-
conformance.

Each discipline is informed during the internal quality audit and non-conformances shall be agreed
and reported in the quality audit reports.

Non-conformances which are highlighted during the purchase & construction phase of a project
are reported by a field close out report which is reviewed by PD for possibly revision of the Project
Quality Assurance System.

17.2 Non-Conformance for Materials supplied by vendor

The vendor has to implement procedures for control and issue of non-conformances to the
vendor’s P/R Requirement. Non-conformances that are highlighted during the procurement phase
of materials are reported with an inspection report to PM.

Nonconforming materials and products purchased by the vendor shall be addressed in accordance
with the “Material and Equipment Inspection & Test Plan/Procedure” for the purposes of Projects.
Any request for deviation or waiver to the COMPANY, for materials or products, resulting from
nonconformance advice, shall be subject to written approval of the COMPANY.

Non-conformities in installation/erection of equipment and materials will be reported, handled in

accordance with “Installation Procedure”.

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